Servo Amplifier Abnormality Detection for Multi-Motor Control

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Solution Overview

Problem

Existing motor-driven machine control systems face challenges in detecting early operation abnormalities caused by aging degradation, as they have limited processing resources to simultaneously generate and transmit motor control commands and perform abnormality determination, leading to potential critical failures.

Innovation Solution

The abnormality determination system includes servo amplifiers that control motors based on motor control commands and compare operation data with reference data to detect abnormalities, while a data collection module manages and transmits data, allowing the upper-level controller to focus on main processing and reducing processing load.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the upper-level controller simultaneously generates motor control commands and performs abnormality determination, then the system can maintain centralized control, but the processing load increases and early abnormality detection capability deteriorates

Engineering Contradiction:

Improveearly abnormality detection capabilityVSAvoidprocessing load on upper-level controller

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the control system into segmented functional units: the upper-level controller focuses on generating motor control commands, while the servo amplifier independently performs abnormality determination by comparing operation data with reference data. This segmentation distributes processing load and enables specialized functions to be performed more effectively.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The servo amplifier acts as an intermediary between the upper-level controller and the motor. It receives control commands, executes them, and simultaneously performs local abnormality detection by comparing operation data with stored reference data, thereby mediating between control functions and monitoring functions without requiring all processing to occur at the upper-level controller.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the system performs comprehensive abnormality determination with multiple motors, then detection accuracy improves, but processing time and computational resources increase

Engineering Contradiction:

Improveabnormality detection accuracyVSAvoidprocessing time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary action by pre-storing reference data representing normal operation patterns in the servo amplifier's memory before actual operation begins. During operation, the system only needs to compare current operation data against these pre-prepared reference patterns, significantly reducing real-time computational requirements while maintaining comprehensive multi-motor detection capability.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11226607B2Abnormality determination system, data transmitter-receptor, motor controller, and method for determining abnormality

Publication Date: 2022.01.18 YASKAWA DENKI KK

AI summary

An abnormality determination system includes motor control circuitry that controls a motor of a motor-driven machine based on a motor control command, and compares operation data of the motor obtained in controlling the motor with reference data stored in a storage to determine whether the motor driven machine has an operation abnormality, upper-level control circuitry that transmits the motor control command to the motor control circuitry, and data transceiver circuitry that transmits and receives the reference data and the operation data to and from the motor control circuitry.